Automatic control and error-proofing system for LED UV curing equipment and energy-saving methods

Abstract

This invention discloses an automatic control and error-proofing system and energy-saving method for LED UV curing equipment, relating to the field of automated UV curing production equipment technology. The system includes: a conveying mechanism, a UV curing mechanism, a feeding identification component, an discharging identification component, an industrial control computer, and a PLC controller. The feeding identification component includes a diffuse reflection photoelectric sensor and a front barcode scanner; the discharging identification component includes a rear barcode scanner; the UV curing mechanism includes independently controllable 365nm and 405nm band LED UV lamp heads; the industrial control computer stores a curing formula database; and the PLC controller has an interlocking control module and a standby control module. This invention achieves forced interlocking between barcode scanning and equipment start / stop, realizing fully automated control and effective error-proofing, significantly reducing the risk of human error and equipment energy consumption.

Description

Technical Field

[0001] This invention relates to the field of automated UV curing production equipment technology, specifically to an automatic control and error-proof system for LED UV curing equipment and an energy-saving and consumption-reducing method. Background Technology

[0002] In manufacturing industries such as photovoltaics, electronics, and printing, UV curing technology is widely used for the rapid curing of materials such as adhesives, inks, and coatings. Traditional UV curing equipment mostly uses mercury lamps as the ultraviolet light source, which has inherent drawbacks such as high heat generation, high energy consumption, short lifespan, and long start-up and preheating times. With the development of solid-state lighting technology, LED UV cold light sources are gradually replacing traditional mercury lamps. LED UV curing equipment has significant advantages such as low power consumption, low operating temperature, concentrated energy, and instantaneous start-up and shutdown, and has become a major direction for technological upgrading in the industry.

[0003] In mass production scenarios, different product models often require different combinations of UV curing energy and wavelengths. For example, some products require 365nm UV light for curing, some require 405nm, and some require simultaneous irradiation with both wavelengths. To achieve process switching between different products, existing LED UV curing equipment typically relies on operators manually adjusting equipment operating parameters, such as manually setting the conveyor belt speed, manually adjusting the UV lamp output power, and manually selecting the wavelength. Based on experience or paper process cards, operators adjust the equipment to the "formula" state corresponding to the product, place the product to be cured at the conveyor belt inlet, and after curing in the UV irradiation zone, the product is discharged from the outlet.

[0004] However, the existing technical solutions mentioned above have certain drawbacks. High risk of human error, lack of hardware error prevention mechanisms, and inability to trace production quality. Different products require specific UV energy and operating speed formulas, relying entirely on manual parameter adjustments, which easily leads to omissions or errors, resulting in poor curing. Furthermore, after manual scanning and registration, there is a risk of operators being lazy or negligent, failing to feed products into the curing equipment and allowing them to flow directly to the next process, generating a large number of uncured defective products. Traditional equipment relies solely on manual self-regulation, lacking mandatory interlocking hardware logic, and does not automatically store the entire curing process data for each product. Therefore, it is impossible to trace and determine whether quality defects are due to incorrect parameter settings or the product not undergoing UV curing, failing to meet ISO quality traceability management requirements. Moreover, once the existing equipment is powered on, the conveyor belt motor and LED UV lamps operate continuously regardless of whether there are products at the feed end. In mass production, the equipment is powered on 24 hours a day, spending most of the time in an idle state without products, resulting in high no-load power consumption and high electricity costs. Simultaneously, the continuous lighting of the LED beads significantly shortens their rated lifespan, and frequent lamp replacements increase equipment maintenance costs. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic control and error-proof system for LED UV curing equipment and an energy-saving and consumption-reducing method to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an automatic control and error-proof system for LED UV curing equipment, comprising: The conveying mechanism includes a conveyor belt and a conveying motor that drives the conveyor belt to rotate. The conveyor belt is provided with a feeding area, a UV curing area and a discharging area in sequence along the conveying direction. The UV curing mechanism is located above the UV curing zone and includes independently controllable 365nm band LED UV lamp heads and 405nm band LED UV lamp heads. The feeding identification component includes a diffuse reflection photoelectric sensor and a front barcode scanning camera. The diffuse reflection photoelectric sensor and the front barcode scanning camera are installed above the feeding area. The diffuse reflection photoelectric sensor is located upstream of the front barcode scanning camera along the conveying direction. The material discharge identification component includes a rear barcode scanner, which is installed above and between the UV curing zone and the material discharge zone. An industrial control computer stores a curing formula database. The curing formula database is indexed by the model code in the product code and stores the corresponding curing formula parameters, including UV band, UV power and conveyor belt speed. The PLC controller is communicatively connected to an industrial computer and is also connected to the rear barcode scanner. The PLC controller includes an interlocking control module and a standby control module. The interlocking control module is connected to the front barcode scanner, the UV curing mechanism, and the conveyor motor, respectively. The standby control module is connected to the diffuse reflection photoelectric sensor.

[0007] Furthermore, the PLC controller also includes a decoding and verification module, which is connected to the front barcode scanner signal and is used to decode the image captured by the front barcode scanner and output a valid decoding signal; The interlocking control module is signal-connected to the decoding verification module and is used to output a lighting control signal to the UV curing mechanism and a start control signal to the conveyor motor only when the valid decoding signal is received, and to keep the conveyor mechanism stationary and the UV curing mechanism off when the valid decoding signal is not received. The standby control module is used to output a standby control signal when the diffuse reflection photoelectric sensor does not output a trigger signal for 30 consecutive seconds, so as to control the conveyor motor to stop running and control the UV curing mechanism to be completely shut down; and to exit the standby state and allow the execution of the control logic of the interlocking control module when the diffuse reflection photoelectric sensor outputs a trigger signal.

[0008] Furthermore, the PLC controller also includes a retry counter, which is signal-connected to the decoding verification module. The retry counter is used to start the retry count when the decoding verification module fails to decode for the first time, and to control the front barcode scanner to perform up to three automatic retries. Each retry is spaced 0.5 seconds apart, and the conveying mechanism remains stationary during the retry period.

[0009] Furthermore, the PLC controller also includes a timing control module, which is connected to the interlocking control module and the conveyor motor signal. The timing control module is used to start an internal delay timer at the same time as the interlocking control module outputs the lighting control signal, and outputs the start control signal to the conveyor motor after a delay of 500 milliseconds. The UV curing mechanism is configured to increase the output power to more than 98% of the set value within 500 milliseconds after receiving the lighting control signal; The timing control module is also used to control the UV curing mechanism to maintain the set power continuously during the operation of the conveyor motor until the rear barcode scanner completes scanning or the product completely leaves the UV curing area.

[0010] Furthermore, the PLC controller also includes a formula retrieval module, which is connected to the front barcode scanner and the industrial control computer respectively. It is used to query and retrieve the corresponding curing formula parameters in the curing formula database based on the model code in the product code decoded by the front barcode scanner. The interlocking control module is also used to output band selection control signals and power setting control signals to the 365nm band LED UV lamp head and the 405nm band LED UV lamp head according to the retrieved curing formula parameters, so as to turn on or off any one group of the 365nm band LED UV lamp head and the 405nm band LED UV lamp head individually or to turn on both groups simultaneously.

[0011] Furthermore, a touch screen, a buzzer, and an emergency stop button are installed on the equipment frame on the side of the UV curing area. The emergency stop button is electrically connected to the PLC controller via a hardware signal. The PLC controller also includes an exception handling module and a storage control module; The anomaly handling module is connected to the decoding and verification module, the touch screen, and the buzzer signal, respectively. The exception handling module is used to output a display drive signal to the touch screen to display a code scanning failure prompt when the decoding and verification module determines that the product code is invalid, and to output an audio drive signal to the buzzer to emit an intermittent short alarm sound, wherein the intermittent short alarm sound sounds for 0.5 seconds and stops for 1 second. The anomaly handling module is also used to output a display drive signal to the touch screen to display a rear barcode scanning anomaly prompt when the product code obtained by the rear barcode scanning camera is inconsistent with or fails to be obtained from the front barcode scanning camera, and to output an audio drive signal to the buzzer to emit an alarm sound. The exception handling module is also used to receive a reset command triggered by the operator, and after the diffuse reflection photoelectric sensor detects the product in place again, it outputs a retry trigger signal to the decoding and verification module to re-trigger the scanning process. The exception handling module is also used to receive a manual release command with administrator privileges and output a forced start signal to the interlock control module; The PLC controller receives the product codes obtained by the front and rear barcode scanners respectively through the storage control module, and sends them to the industrial computer for associated storage to form a fixed record; When the emergency stop button is pressed, the PLC controller immediately cuts off the power to the 365nm band LED UV lamp head, the 405nm band LED UV lamp head, and the conveyor motor, and locks the fault state; after the emergency stop button is rotated to reset and a fault reset command is received on the touch screen, the PLC controller performs a self-test, and returns to the standby state after the self-test passes.

[0012] This invention also provides an energy-saving and consumption-reducing method for an automatic control and error-proof system for LED UV curing equipment, which uses the system described above and includes the following steps: Step S1, Standby Detection: The diffuse reflection photoelectric sensor detects whether the product is in place. If no product arrival signal is detected for 30 consecutive seconds, the PLC controller controls the conveyor mechanism to stop operating and controls the UV curing mechanism to completely shut down, maintaining the standby state. When a product arrival signal is detected, the diffuse reflection photoelectric sensor outputs a trigger signal to the PLC controller, and Step S2 is executed. Step S2, front automatic barcode scanning: The PLC controller controls the front barcode scanning camera to take a single shot based on the trigger signal output by the diffuse reflection photoelectric sensor, identify the product code carried by the product located on the conveyor mechanism, and send the decoding result to the PLC controller; Step S3, start permission determination: The PLC controller determines whether the decoding result sent in step S2 meets the valid decoding conditions. If yes, then proceed to step S4; if no, then control the front barcode scanner to perform up to three automatic retries, with a 0.5-second interval between each retries, and keep the conveyor mechanism stationary during this period; if the valid decoding conditions are still not met after three retries, then keep the conveyor mechanism stationary and turn off the UV curing mechanism, and proceed to step S9. Step S4, Formula Retrieval: The PLC controller queries and retrieves the corresponding curing formula parameters from the curing formula database of the industrial control computer based on the model code in the decoded product code. The curing formula parameters include UV band, UV power and conveyor belt speed. Step S5, timing control: The PLC controller sends a lighting command to the UV curing mechanism according to the retrieved curing formula parameters, and sends a start command to the conveying mechanism after a delay of 500 milliseconds after sending the lighting command; During the operation of the conveying mechanism, the UV curing mechanism continuously maintains the set power until the rear barcode scanner completes scanning or the product completely leaves the UV curing area. Step S6, UV curing: The product enters the UV curing zone along with the conveying mechanism, and the UV curing mechanism emits ultraviolet light to the product according to the retrieved curing formula parameters; Step S7, Automatic Scanning: The product code carried by the solidified product is identified by the rear scanning camera; Step S8, subsequent code scanning verification: The PLC controller determines whether the product code was successfully obtained in step S7, and whether the product code is consistent with the product code obtained in step S2; if consistent, proceed to step S10; if inconsistent or acquisition fails, generate an exception flag and proceed to step S10. Step S9, Abnormal Handling: The PLC controller controls the touch screen to display a barcode scanning failure message and controls the buzzer to emit an intermittent alarm sound to maintain the abnormal pause state; after receiving a reset command triggered by the operator, the PLC controller clears the alarm state and returns to step S1; or after receiving a manual release command with administrator privileges, it forcibly starts the conveying mechanism and the UV curing mechanism to execute the UV curing step, and controls the industrial control computer to record the manual release abnormal log, and then executes step S10; Step S10, Data Association and Storage: The PLC controller sends the product code obtained by the previous scan, the product code obtained by the subsequent scan, the abnormal mark, and the manual release abnormal log to the industrial control computer for association and storage, forming a complete solidified record, and then returns to step S1; Step S11, Emergency Stop Processing: During any of the execution processes from steps S1 to S10, when the emergency stop button is pressed, the PLC controller immediately cuts off the power supply to the UV curing mechanism and the conveying mechanism, and locks the fault state; after the emergency stop button is rotated to reset and a fault reset command is received, a self-test is performed, and after the self-test passes, the process returns to step S1.

[0013] Furthermore, in step S3, the effective decoding condition refers to: successfully extracting the complete product code data block from a single captured image, and verifying the data integrity and absence of errors through a verification algorithm; for QR codes, successful decoding is allowed within the error correction rate range of 15% to 25%; for barcodes, partial character substitution is not allowed. The UV curing mechanism will increase its output power to more than 98% of the set value within 500 milliseconds after receiving the lighting command.

[0014] Furthermore, in step S6, the PLC controller, based on the UV band parameters in the retrieved curing formula parameters, individually turns on or off any one of the 365nm band LED UV lamp heads and the 405nm band LED UV lamp heads, or simultaneously turns on both groups. The PLC controller sets the output power of the UV curing mechanism according to the retrieved UV power parameters, and sets the operating speed of the conveyor motor according to the retrieved conveyor belt speed parameters. During the curing process, the PLC controller monitors the equipment over-temperature signal and motor overload signal in real time. When over-temperature or overload occurs, it immediately cuts off the power supply to the UV curing mechanism and the conveyor motor, records the fault log, and then returns to step S1.

[0015] Further, in step S10, the curing record includes the complete product code, previous scan timestamp, subsequent scan timestamp, curing duration, formula name used, actual UV power, actual delivery speed, equipment number, and operator ID; the industrial control computer provides a curing history query interface, which supports searching by product code, curing date and time period, product model code, and at least one condition in the curing result, and supports exporting to CSV or Excel format files; The solidified formula database is password protected, allowing only authorized administrators to modify formula parameters, and the industrial control computer records formula modification logs; the industrial control computer adopts a cyclic overwrite storage strategy for solidified records, and automatically deletes the earliest historical records from three months ago when the storage capacity reaches a preset threshold.

[0016] The technical effects and advantages provided by the present invention in the above technical solution are as follows: 1. Automatic identification of product codes by the front barcode scanner serves as the necessary and only hardware interlock condition for equipment startup. Only after the front barcode scanner successfully decodes and retrieves the valid formula can the interlock control module of the PLC controller allow the conveyor belt to start and the UV lamp to light up. If the barcode scan fails or the product is not placed, the equipment will remain absolutely stationary and off, physically eliminating operational loopholes such as "manual parameter adjustment errors" and "products left out after scanning". The error-proof effect does not rely on the operator's self-discipline. 2. With the dual-scanning configuration of a barcode scanner at the inlet and a barcode scanner at the outlet, the system encodes and records each product entering and leaving the curing area, and stores the data from the two scans together to form a complete curing record containing information such as product ID, curing time, formula parameters, and equipment status. This record is non-repudiable and cannot be forged afterward, and can strictly prove that each product has indeed undergone the curing process, meeting the strict requirements of the ISO quality management system for process traceability. 3. By adopting a refined timing control strategy of pre-lighting the UV lamp and delaying the start of the conveyor belt, after the front scanning is successful, the PLC controller immediately lights up the UV lamp. After the output power of the LED UV lamp stabilizes and rises to more than 98% of the set value within 500 milliseconds, the conveyor belt is then started to send the product into the irradiation area. This timing control completely eliminates the problem of insufficient curing energy caused by the unstable power of the UV lamp in the front of the product, ensuring that the product receives uniform curing energy along its entire length. 4. By utilizing the instant-on, preheat-free technology of LED UV lamps, a mechanism was designed to automatically enter standby mode after 30 seconds of no product usage. In standby mode, the conveyor belt completely stops operating, the UV lamps are completely turned off, and only the controller and cooling fan maintain low-power operation. This significantly reduces standby power consumption, greatly shortens the actual lighting time of the UV lamp heads, and improves the effective lifespan of the LED lamp heads. 5. Operators only need to complete the feeding and receiving actions, without manually adjusting any equipment parameters. The system automatically completes the entire process of barcode scanning and identification, formula retrieval, band selection, power setting, speed adjustment, curing execution, and data recording, greatly reducing the number of operations, lowering the probability of human error, and improving production efficiency. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0018] Figure 1 This is a schematic diagram of the automatic control and error-proof system for the LED UV curing equipment of the present invention; Figure 2 For the present invention Figure 1 A sectional view; Figure 3 This is a diagram showing the signal connection relationship of the PLC controller of the present invention; Figure 4 This is a schematic diagram of the PLC controller module of the present invention; Figure 5 This is a flowchart of the automatic control error prevention method of the present invention.

[0019] Explanation of reference numerals in the attached figures: 1. Conveyor belt; 2. Conveyor motor; 3. UV curing mechanism; 4. Diffuse reflection photoelectric sensor; 5. Front barcode scanner; 6. Touch screen; 7. Buzzer; 8. Emergency stop button; 9. Rear barcode scanner. Detailed Implementation

[0020] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0021] This invention provides, for example Figures 1 to 4 The automatic control and error-proof system of the LED UV curing equipment shown includes: a conveying mechanism, a UV curing mechanism 3, a feeding identification component, a discharging identification component, an industrial computer, and a PLC controller.

[0022] The conveying mechanism includes a conveyor belt 1 and a conveyor motor 2 that drives the conveyor belt 1 to rotate. The conveyor belt 1 is sequentially arranged with a feeding area, a UV curing area, and a discharging area along the conveying direction. The conveyor belt 1 is used to carry and transport the product to be cured, and the conveyor motor 2 is started, stopped, and speed adjusted under the control of a PLC controller.

[0023] In this embodiment, the speed of conveyor belt 1 can be automatically set according to the speed parameters of conveyor belt 1 retrieved from the curing formula database.

[0024] The UV curing mechanism 3 is positioned above the UV curing zone. It comprises independently controllable 365nm and 405nm LED UV lamp heads. Each of the two LED UV lamp heads can be individually turned on or off, or both can be turned on simultaneously, depending on the UV band parameters in the curing formula. The UV curing mechanism 3 is configured to increase its output power to at least 98% of a set value within 500 milliseconds of receiving a ignition control signal. During the curing process, the PLC controller sets the output power of the UV curing mechanism 3 based on the retrieved UV power parameters.

[0025] The feeding identification component includes a diffuse reflection photoelectric sensor 4 and a front barcode scanning camera 5. The diffuse reflection photoelectric sensor 4 and the front barcode scanning camera 5 are installed above the feeding area, and the diffuse reflection photoelectric sensor 4 is located upstream of the front barcode scanning camera 5 along the conveying direction.

[0026] The diffuse reflection photoelectric sensor 4 is used to detect whether the product is in place. When the product is placed in the feeding area, it blocks the modulated light emitted by the transmitter, causing diffuse reflection. The receiver captures the reflected light and converts it into an electrical signal. When the intensity of the reflected light exceeds a preset switching threshold, the sensor outputs a trigger signal to the PLC controller. After receiving the trigger signal, the PLC controller sends a shooting command to the barcode scanner within less than 10 milliseconds. The camera then takes a single shot and decodes it. The sensitivity of the diffuse reflection photoelectric sensor 4 can be adjusted by changing the switching threshold to accommodate variations in product thickness and surface reflectivity.

[0027] The front-facing barcode scanner 5 is used to automatically identify the product codes (QR codes or barcodes) carried by products located on the conveyor mechanism. The front-facing barcode scanner 5 sends the captured images to the decoding and verification module of the PLC controller for decoding. For QR codes, successful decoding is allowed within a 15% to 25% error correction rate range; for barcodes, partial character substitution is not allowed.

[0028] The discharge identification component includes a rear barcode camera 9, which is installed above the UV curing zone and the discharge zone. It is used to identify the product code carried by the cured product and send the acquired product code to the PLC controller for comparison and verification with the product code acquired by the front barcode camera 5.

[0029] The industrial control computer stores a curing formula database. The curing formula database is indexed by the model code in the product code and stores the corresponding curing formula parameters. The curing formula parameters include UV band, UV power and conveyor belt speed.

[0030] In this embodiment, the first 8 digits of the product code are set as the product model code, which forms a one-to-one mapping with the model code field in the database. All formula parameters are stored in the local solid-state drive of the industrial control computer as an SQLite database file. When the system starts, the PLC controller establishes communication with the industrial control computer and loads the currently available formula list. The solidified formula database is password protected and can only be modified by authorized administrators through the formula management interface of the touch screen 6. The operation log records the modifier and the modification time.

[0031] The industrial control computer also provides a history record query interface, supporting searches by product code, curing date / time period, product model code, and at least one of the following conditions in the curing result. It also supports exporting to CSV or Excel format files. The industrial control computer employs a cyclic overwrite storage strategy for the cured records; when the storage capacity reaches a preset threshold, it automatically deletes the earliest historical records dating back three months.

[0032] The PLC controller is communicatively connected to the industrial computer and is also signal-connected to components such as the rear barcode scanner 9, conveyor motor 2, UV curing mechanism 3, front barcode scanner 5, diffuse reflection photoelectric sensor 4, touch screen 6, buzzer 7, and emergency stop button 8. The PLC controller includes an interlocking control module, a standby control module, a decoding and verification module, a retry counter, a timing control module, a recipe retrieval module, an exception handling module, and a storage control module.

[0033] The functions and signal connections of each module are as follows:

[0034] The decoding and verification module is connected to the front barcode scanner 5 and is used to decode the images captured by the front barcode scanner 5 and output a valid decoding signal. A valid decoding signal means that a complete product code data block is successfully extracted from a single captured image, and the data is verified to be complete and error-free through a verification algorithm. If the first decoding fails, the PLC controller does not send a start signal, and the equipment remains in standby mode.

[0035] The interlocking control module is connected to the decoding and verification module, the front barcode camera 5, the UV curing mechanism 3, and the conveyor motor 2. The interlocking control module outputs a lighting control signal to the UV curing mechanism 3 and a start control signal to the conveyor motor 2 only when a valid decoding signal is received. When no valid decoding signal is received, the conveyor mechanism remains stationary and the UV curing mechanism 3 is turned off. The interlocking control module also outputs band selection control signals and power setting control signals to the 365nm and 405nm LED UV lamp heads according to the retrieved curing formula parameters, to individually turn on or off any one group of the 365nm and 405nm LED UV lamp heads or to simultaneously turn on both groups. The interlocking control module can also receive a forced start signal from the anomaly handling module to perform a manual release operation.

[0036] The standby control module is signal-connected to the diffuse reflection photoelectric sensor 4. The standby control module is used to output a standby control signal when the diffuse reflection photoelectric sensor 4 does not output a trigger signal for thirty consecutive seconds, thereby controlling the conveyor motor 2 to stop operating and controlling the UV curing mechanism 3 to completely shut down; and to exit the standby state and allow the execution of the control logic of the interlocking control module when the diffuse reflection photoelectric sensor 4 outputs a trigger signal. In the standby state, the conveyor belt 1 completely stops operating, the UV lamp is completely turned off, and only the controller and cooling fan maintain low-power operation. The retry counter is signal-connected to the decoding verification module and is used to start the retry count when the decoding verification module fails to decode for the first time. It also controls the front scanning camera 5 to perform up to three automatic retries, with each retrieval spaced 0.5 seconds apart. During the retries, the conveying mechanism remains stationary. If the valid decoding conditions are still not met after three retries, the code is determined to be invalid, and the system enters an abnormal pause state. The timing control module is signal-connected to the interlocking control module and the conveyor motor 2. It is used to activate an internal delay timer simultaneously with the interlocking control module outputting the lighting control signal. After a delay of 500 milliseconds, it outputs the start control signal to the conveyor motor 2. This delay ensures that the power output of the LED UV lamp is stable at over 98% of the set value before the current product enters the irradiation area directly below the UV lamp, thus eliminating the risk of insufficient curing energy. The timing control module is also used to control the UV curing mechanism 3 to continuously maintain the set power during the operation of the conveyor motor 2 until the rear barcode scanner 9 completes scanning or the product completely leaves the UV curing area.

[0037] The formula retrieval module is connected to both the front barcode scanner 5 and the industrial control computer. It is used to query and retrieve the corresponding curing formula parameters from the curing formula database based on the model code in the product code decoded by the front barcode scanner 5. If the industrial control computer fails to retrieve the formula (no matching model code), the system enters an abnormal pause state.

[0038] The anomaly handling module is connected to the decoding and verification module, the touchscreen 6, and the buzzer 7. When the decoding and verification module determines that the product code is invalid, the anomaly handling module outputs a display drive signal to the touchscreen 6 to display a scanning failure message, and outputs an audio drive signal to the buzzer 7 to emit an intermittent, short alarm sound (0.5 seconds on / 1 second off). The anomaly handling module is also used to output a display drive signal to the touchscreen 6 to display a subsequent scanning anomaly message and output an audio drive signal to the buzzer 7 to emit an alarm sound when the product code acquired by the rear scanning camera 9 is inconsistent with or fails to acquire the product code acquired by the front scanning camera 5. The anomaly handling module is also used to receive a reset command triggered by the operator and, after waiting for the diffuse reflection photoelectric sensor 4 to detect the product in place again, output a retry trigger signal to the decoding and verification module to re-trigger the scanning process. The anomaly handling module is also used to receive a manual release command with administrator privileges and output a forced start signal to the interlocking control module. The PLC controller receives the product codes acquired by the front barcode scanner 5 and the rear barcode scanner 9 respectively through the storage control module, and sends them to the industrial control computer for associated storage, forming a solidified record. The solidified record includes the complete product code, the front barcode timestamp, the rear barcode timestamp, the solidification duration, the name of the formula used, the actual UV power, the actual conveying speed, the equipment number, and the operator ID.

[0039] A touchscreen 6, a buzzer 7, and an emergency stop button 8 are installed on the equipment frame on the side of the UV curing area. The emergency stop button 8 is electrically connected to the PLC controller via a hardware signal. When the emergency stop button 8 is pressed, the PLC controller immediately cuts off the power to the 365nm band LED UV lamp head, the 405nm band LED UV lamp head, and the conveyor motor 2, and latches the fault state. After the emergency stop button 8 is rotated back to its original position and a fault reset command is received from the touchscreen 6, the PLC controller performs a self-test, and returns to standby mode after the self-test passes.

[0040] like Figure 5 As shown, the present invention also provides an energy-saving and consumption-reducing method for an automatic control and error-proof system for LED UV curing equipment, which uses the system described above and includes the following steps: Step S1, Standby Detection: The diffuse reflection photoelectric sensor 4 detects whether the product is in place. If no product arrival signal is detected for thirty consecutive seconds, the standby control module of the PLC controller controls the conveyor mechanism to stop operating and controls the UV curing mechanism 3 to completely shut down, maintaining a standby state. In the standby state, the conveyor belt 1 completely stops operating, the UV lamp is completely turned off, and only the controller and cooling fan maintain low power consumption operation. When a product arrival signal is detected, the diffuse reflection photoelectric sensor 4 outputs a trigger signal to the PLC controller, executing step S2; Step S2, Automatic QR Code Scanning: The PLC controller sends a shooting command to the front barcode scanner 5 within less than 10 milliseconds based on the trigger signal output by the diffuse reflection photoelectric sensor 4, controls the front barcode scanner 5 to take a single shot, identifies the product code (QR code or barcode) carried by the product located on the conveyor mechanism, and sends the decoding result to the PLC controller. Step S3, initiate license determination: The PLC controller determines whether the decoding result sent in step S2 meets the valid decoding conditions. The valid decoding conditions refer to: successfully extracting the complete product code data block from a single captured image, and verifying the data integrity and absence of errors through a verification algorithm; for QR codes, successful decoding is allowed within a 15% to 25% error correction rate range; for barcodes, partial character substitution is not allowed.

[0041] If the decoding result meets the valid decoding conditions, proceed to step S4; otherwise, the retry counter of the PLC controller starts retry counting, controlling the front barcode scanner 5 to perform up to three automatic retries, with each retrieval interval of 0.5 seconds, and the conveyor mechanism remains stationary during this period. If the valid decoding conditions are still not met after three retries, the conveyor mechanism remains stationary and the UV curing mechanism 3 is turned off, and proceed to step S9. Step S4, Recipe Preparation: The PLC controller retrieves the corresponding curing formula parameters from the curing formula database of the industrial computer using the formula retrieval module based on the model code (first 8 digits) in the decoded product code. The curing formula parameters include UV band, UV power, and conveyor belt (1) speed. If the industrial computer fails to retrieve the formula (no matching model code), the system enters an abnormal pause state; Step S5, Timing Control: The PLC controller sends a lighting command (t=0 seconds) to the UV curing mechanism 3 based on the retrieved curing formula parameters. Within 500 milliseconds of receiving the lighting command, the UV curing mechanism 3 increases its output power to over 98% of the set value. After sending the lighting command, the PLC controller starts an internal delay timer. After a delay of 500 milliseconds (t=0.5 seconds), it sends a start command to the conveyor mechanism. This delay ensures that the power output of the LED UV lamp is stable at over 98% of the set value before the current product enters the irradiation area directly below the UV lamp, thus eliminating the risk of insufficient curing energy. During the operation of the conveyor mechanism, the UV curing mechanism 3 maintains the set power until the rear barcode scanner 9 completes scanning or the product completely leaves the UV curing area. Step S6, UV curing: The product enters the UV curing zone via the conveyor mechanism, and the UV curing mechanism 3 emits ultraviolet light onto the product according to the retrieved curing formula parameters. The PLC controller, based on the UV band parameters in the retrieved curing formula parameters, individually turns on or off any one of the 365nm band LED UV lamps and the 405nm band LED UV lamps, or simultaneously turns on both. The PLC controller sets the output power of the UV curing mechanism 3 according to the retrieved UV power parameters, and sets the operating speed of the conveyor motor 2 according to the retrieved conveyor belt 1 speed parameters.

[0042] During the curing process, the PLC controller monitors the equipment over-temperature signal and motor overload signal in real time. When over-temperature or overload occurs, it immediately cuts off the power supply to the UV curing mechanism 3 and the conveyor motor 2, records the fault log, and then returns to step S1. Step S7, then automatic QR code scanning: The product code carried by the solidified product is identified by the rear barcode camera 9, and the obtained product code is sent to the PLC controller; Step S8, subsequent barcode verification: The PLC controller determines whether the product code was successfully obtained in step S7, and whether the product code is consistent with the product code obtained in step S2. If they are consistent, proceed to step S10; if they are inconsistent or the acquisition failed, an exception flag is generated and step S10 is executed. Step S9, Exception Handling: If the valid decoding condition is still not met after three retries in step S3, or if the recipe query fails in step S4, the abnormal handling module of the PLC controller controls the touch screen 6 to display a barcode scanning failure message and controls the buzzer 7 to emit an intermittent alarm sound (0.5 seconds on / 1 second off), maintaining the abnormal pause state. The conveyor belt 1 remains stationary, and the UV lamp remains off.

[0043] After receiving a reset command triggered by the operator, the PLC controller clears the alarm status and returns to step S1; or after receiving a manual release command with administrator privileges, the abnormal handling module outputs a forced start signal to the interlock control module, forcibly starts the conveying mechanism and the UV curing mechanism 3 to execute the UV curing step, and controls the industrial control computer to record the manual release abnormal log, and then executes step S10. Step S10, Data Association Storage: The PLC controller sends the product code obtained from the previous scan, the product code obtained from the subsequent scan, the abnormal marker, and the manual release abnormal log to the industrial control computer for associated storage, forming a complete and fixed record, and then returns to step S1.

[0044] The curing record includes the complete product code, previous scan timestamp, subsequent scan timestamp, curing duration, formula name used, actual UV power, actual delivery speed, equipment number, and operator ID. The industrial control computer provides a curing history query interface, supporting searches by product code, curing date / time period, product model code, and at least one of the following conditions in the curing result. It also supports exporting to CSV or Excel format files. The curing formula database is password protected, allowing only authorized administrators to modify formula parameters, and the industrial control computer records formula modification logs. The industrial control computer employs a cyclic overwrite storage strategy for curing records; when the storage capacity reaches a preset threshold, it automatically deletes historical records older than three months. In step S11, during any of the execution processes from steps S1 to S10, when the emergency stop button 8 is pressed, the PLC controller immediately cuts off the power supply to the UV curing mechanism 3 and the conveying mechanism, and locks the fault state; after the emergency stop button 8 is rotated to reset and a fault reset command is received on the touch screen 6, the PLC controller performs a self-test, and returns to step S1 after the self-test passes.

[0045] The PLC controller in this system implements equipment control in the form of a state machine. The equipment has five possible states: standby power-saving state, barcode scanning and identification state, fixed operation state, abnormal pause state, and fault shutdown state. The transition conditions and actions between each state are shown in the table below:

[0046] Furthermore, the trigger condition for transitioning from State 5 (fault shutdown) to State 1 (standby energy saving) is: the emergency stop button is rotated to reset and a fault reset command is received from the touchscreen. The transition process is as follows: the PLC controller performs a self-test, and after passing the self-test, it returns to the standby energy saving state.

[0047] The specific transition conditions and actions between each state are as follows: State 1: Standby power saving After powering on and completing its self-test, the equipment enters a standby power-saving state. In this state, conveyor belt 1 stops operating, UV curing mechanism 3 is completely shut down, and only the PLC controller and cooling fan maintain low-power operation.

[0048] The trigger condition for transitioning from state one to state two is: the diffuse reflection photoelectric sensor 4 detects that the product is in place, or the operator manually starts the process by clicking the touch screen 6.

[0049] The conversion action is as follows: the PLC controller sends a trigger command to the front barcode scanner 5.

[0050] Status 2: QR code recognition In this state, the front barcode scanner 5 captures and decodes the product code.

[0051] If decoding is successful and the industrial control computer successfully queries the recipe, the process transitions from state two to state three.

[0052] The conversion action is as follows: the PLC controller sends a lighting control signal to the UV curing mechanism 3 (t=0 seconds), starts the internal delay timer, and sends a start control signal to the conveyor motor 2 after a delay of 500 milliseconds.

[0053] If decoding fails and the number of retries is less than or equal to three, then maintain state two and automatically retry (with an interval of 0.5 seconds), while the conveyor mechanism remains stationary.

[0054] If decoding fails and the number of retries exceeds three, or if the industrial control computer fails to query the recipe, the process transitions from state two to state four.

[0055] The switching action is as follows: conveyor belt 1 stops, buzzer 7 emits intermittent short alarm sounds (0.5 seconds on / 1 second off), and touch screen 6 displays fault information.

[0056] State 3: Solidification Operation In this state, the UV curing unit 3 continuously irradiates at the set power, and the conveyor belt 1 runs at the set speed, with the products passing through the UV curing zone sequentially to complete the curing process. The PLC controller monitors the equipment's over-temperature signal and motor overload signal in real time.

[0057] The trigger condition for transitioning from state three to state one is: the rear barcode scanner 9 completes scanning and the product completely leaves the UV curing area (the diffuse reflection photoelectric sensor 4 detects the product's trailing edge). The transition action is: the conveyor belt 1 stops, the UV curing mechanism 3 shuts down, and the curing record is automatically stored in the industrial control computer.

[0058] Another trigger condition for transitioning from state three to state one is: the operator presses the stop button (forced shutdown). The transition action is: conveyor belt 1 stops, and UV curing mechanism 3 shuts down.

[0059] Status 4: Abnormal Pause In this state, conveyor belt 1 remains stationary, UV lamps remain off, touchscreen 6 displays abnormal information, and buzzer 7 sounds an alarm.

[0060] The trigger condition for transitioning from state four to state two is: the operator clicks the reset / retry button on touchscreen 6. The transition action is: clear the alarm state, and wait for diffuse reflection photoelectric sensor 4 to detect the product's arrival again before re-triggering the barcode scanning process.

[0061] The trigger condition for transitioning from state four to state three is: the operator clicks the jump / manual release button (administrator privileges required). The transition actions are: recording a manual release exception log, the interlock control module receiving a forced start signal, and forcibly starting the conveyor mechanism and UV curing mechanism 3.

[0062] Status 5: Malfunction shutdown In any state, pressing the emergency stop button 8 (hardware signal, highest priority) will immediately put the system into a fault shutdown state. The transition action is as follows: the PLC controller immediately cuts off the power to the UV curing mechanism 3 and the conveying mechanism, and latches the fault state.

[0063] The trigger condition for transitioning from state five to state one is: the emergency stop button 8 is rotated to reset and a fault reset command is received from the touchscreen 6. The transition action is: the PLC controller performs a self-test, and returns to the standby power-saving state after the self-test passes.

[0064] Energy saving and consumption reduction effect of this technical solution: This invention utilizes the instant-on, preheat-free technology of LED UV lamps and designs a mechanism that automatically enters standby mode after 30 seconds of inactivity, achieving significant energy savings and reduced consumption. The following are comparison data before and after the modification: Standby power consumption comparison Before the upgrade, the conveyor belt ran continuously and the UV lamps remained on when the equipment was in standby mode, consuming approximately 3000W. After the upgrade, the conveyor belt stopped, the UV lamps were completely turned off, and only the controller and fan maintained low-power operation, consuming approximately 50W. Standby power consumption was reduced by approximately 98%.

[0065] Energy consumption comparison under typical operating conditions Taking a typical operating condition as an example: 1 pallet of products is processed every 1 minute (600pcs / pallet), and the factory's daily production capacity is 120,000pcs (24 hours). Therefore, the UV lamp only needs to work for: 120,000 ÷ 600 × 1 = 200 minutes, with a utilization rate of: 200 minutes ÷ (24 hours × 60 minutes) = 13.9%. Before the upgrade, the equipment continuously operated at full power (3000W). After the upgrade, it only operates at full power when the product barcode is valid (the LED only needs to work for 200 minutes per day), reducing daily energy consumption by approximately 86.1%.

[0066] Extended lifespan of UV lamps Before the upgrade, the UV lamp was lit continuously for about 24 hours a day. After the upgrade, it is actually lit for about 200 minutes a day (about 1 / 7 of 24 hours). The lifespan of the LED lamp head is expected to be extended by about 7 times.

[0067] The energy-saving and consumption-reducing effects mentioned above are summarized in the table below:

[0068] Alternative solution: Those skilled in the art will understand that various improvements and substitutions can be made to this invention without departing from its principles, and these improvements and substitutions should also be considered within the scope of protection of this invention. The following are some alternative solutions: Alternative identification methods: The front and rear barcode scanning cameras 9 can be either line scan cameras or area scan cameras, or laser barcode scanners can be used instead. Alternatively, RFID readers can replace QR code scanning cameras, and products can be labeled with RFID tags to achieve contactless identification.

[0069] Control unit replacement: The control logic can be fully implemented by an industrial computer (soft PLC solution), with the PLC only serving as an execution unit; or a microcontroller / embedded system can be used to replace the PLC.

[0070] Camera configuration alternative: A third camera can be added for re-inspection as needed. A barcode scanner and a product arrival sensor are installed at the feed inlet. The system only activates after the sensor detects the product and the camera successfully scans the barcode. A camera is not required in the post-curing area, but this will result in the loss of traceability functionality.

[0071] Alternative for curing detection: Scan the code at the inlet and weigh simultaneously, then weigh again at the outlet. Determine whether the material has cured by observing the weight change (only applicable to materials that show significant weight loss after curing).

[0072] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. An automatic control and error-proof system for LED UV curing equipment, characterized in that, include: The conveying mechanism includes a conveyor belt (1) and a conveying motor (2) for driving the conveyor belt (1) to rotate. The conveyor belt (1) is provided with a feeding area, a UV curing area and a discharging area in sequence along the conveying direction. The UV curing mechanism (3) is located above the UV curing area. The UV curing mechanism (3) includes independently controllable 365nm band LED UV lamp heads and 405nm band LED UV lamp heads. The feeding identification component includes a diffuse reflection photoelectric sensor (4) and a front barcode scanner (5). The diffuse reflection photoelectric sensor (4) and the front barcode scanner (5) are installed above the feeding area. The diffuse reflection photoelectric sensor (4) is located upstream of the front barcode scanner (5) along the conveying direction. The material discharge identification component includes a rear barcode camera (9), which is installed above the UV curing zone and the material discharge zone. An industrial computer, which stores a curing formula database. The curing formula database is indexed by the model code in the product code and stores the corresponding curing formula parameters. The curing formula parameters include UV band, UV power and conveyor belt (1) speed. The PLC controller is connected to the industrial computer and to the rear barcode scanner (9). The PLC controller includes an interlock control module and a standby control module. The interlock control module is connected to the front barcode scanner (5), the UV curing mechanism (3) and the conveyor motor (2) respectively. The standby control module is connected to the diffuse reflection photoelectric sensor (4).

2. The automatic control and error-proof system for LED UV curing equipment according to claim 1, characterized in that: The PLC controller also includes a decoding and verification module, which is connected to the front barcode camera (5) and is used to decode the image captured by the front barcode camera (5) and output a valid decoding signal. The interlock control module is signal-connected to the decoding verification module and is used to output a lighting control signal to the UV curing mechanism (3) and a start control signal to the conveying motor (2) only when the valid decoding signal is received. When the valid decoding signal is not received, the conveying mechanism is kept stationary and the UV curing mechanism (3) is turned off. The standby control module is used to output a standby control signal when the diffuse reflection photoelectric sensor (4) does not output a trigger signal for 30 consecutive seconds, so as to control the conveyor motor (2) to stop running and control the UV curing mechanism (3) to be completely shut down; and to exit the standby state and allow the execution of the control logic of the interlocking control module when the diffuse reflection photoelectric sensor (4) outputs a trigger signal.

3. The automatic control and error-proof system for LED UV curing equipment according to claim 2, characterized in that: The PLC controller also includes a retry counter, which is connected to the decoding verification module signal. It is used to start the retry count when the decoding verification module fails to decode for the first time, and control the front scanning camera (5) to perform up to three automatic retryes. Each retry is spaced 0.5 seconds apart, and the conveying mechanism remains stationary during the retry.

4. The automatic control and error-proof system for LED UV curing equipment according to claim 3, characterized in that: The PLC controller also includes a timing control module, which is connected to the interlocking control module and the conveyor motor (2) by signal. The timing control module is used to start an internal delay timer at the same time as the interlocking control module outputs the lighting control signal. After a delay of 500 milliseconds, the start control signal is output to the conveyor motor (2). The UV curing mechanism (3) is configured to increase the output power to more than 98 percent of the set value within 500 milliseconds after receiving the lighting control signal; The timing control module is also used to control the UV curing mechanism (3) to maintain the set power continuously during the operation of the conveyor motor (2) until the rear barcode camera (9) completes scanning or the product completely leaves the UV curing area.

5. The automatic control and error-proof system for LED UV curing equipment according to claim 2, characterized in that: The PLC controller also includes a formula retrieval module, which is connected to the front barcode camera (5) and the industrial control computer respectively. It is used to query and retrieve the corresponding curing formula parameters in the curing formula database according to the model code in the product code decoded by the front barcode camera (5). The interlocking control module is also used to output band selection control signals and power setting control signals to the 365nm band LED UV lamp head and the 405nm band LED UV lamp head according to the retrieved curing formula parameters, so as to turn on or off any one group of the 365nm band LED UV lamp head and the 405nm band LED UV lamp head individually or to turn on both groups simultaneously.

6. The automatic control and error-proof system for LED UV curing equipment according to claim 1, characterized in that: A touch screen (6), a buzzer (7), and an emergency stop button (8) are installed on the equipment frame on the side of the UV curing area. The emergency stop button (8) is electrically connected to the PLC controller via a hardware signal. The PLC controller also includes an exception handling module and a storage control module; The anomaly handling module is connected to the decoding and verification module, the touch screen (6), and the buzzer (7) respectively; The exception handling module is used to output a display drive signal to the touch screen (6) to display a code scanning failure prompt when the decoding verification module determines that the product code is invalid, and to output an audio drive signal to the buzzer (7) to emit an intermittent short alarm sound, wherein the intermittent short alarm sound sounds for 0.5 seconds and stops for 1 second. The exception handling module is also used to output a display drive signal to the touch screen (6) to display the rear barcode abnormality prompt information when the product code obtained by the rear barcode camera (9) is inconsistent with the product code obtained by the front barcode camera (5) or the acquisition fails, and to output an audio drive signal to the buzzer (7) to emit an alarm sound. The exception handling module is also used to receive the reset command triggered by the operator, and after the diffuse reflection photoelectric sensor (4) detects the product in place again, it outputs a retry trigger signal to the decoding verification module to re-trigger the scanning process. The exception handling module is also used to receive a manual release command with administrator privileges and output a forced start signal to the interlock control module; The PLC controller receives the product codes obtained by the front barcode scanner (5) and the rear barcode scanner (9) respectively through the storage control module, and sends them to the industrial computer for associated storage to form a fixed record; When the emergency stop button (8) is pressed, the PLC controller immediately cuts off the power supply to the 365nm band LED UV lamp head, the 405nm band LED UV lamp head and the conveyor motor (2), and locks the fault state; after the emergency stop button (8) is rotated to reset and a fault reset command is received on the touch screen (6), the PLC controller performs a self-test, and returns to the standby state after the self-test is passed.

7. An energy-saving and consumption-reducing method for an automatic control and error-proof system for LED UV curing equipment, employing the system described in any one of claims 1 to 6, characterized in that, Includes the following steps: Step S1, standby detection: The diffuse reflection photoelectric sensor (4) detects whether the product is in place. When no product arrival signal is detected for 30 consecutive seconds, the PLC controller controls the conveying mechanism to stop running and controls the UV curing mechanism (3) to be completely shut down, maintaining the standby state; when the product arrival signal is detected, the diffuse reflection photoelectric sensor (4) outputs a trigger signal to the PLC controller, and steps S2 are executed. Step S2, front automatic barcode scanning: The PLC controller controls the front barcode scanning camera (5) to take a single shot based on the trigger signal output by the diffuse reflection photoelectric sensor (4), identify the product code carried by the product located on the conveyor mechanism, and send the decoding result to the PLC controller; Step S3, start permission determination: The PLC controller determines whether the decoding result sent in step S2 meets the valid decoding conditions. If yes, then step S4 is executed; if no, then the front barcode scanner (5) is controlled to perform up to three automatic retryes, with a retry interval of 0.5 seconds, and the conveying mechanism is kept stationary during this period; if the valid decoding conditions are still not met after three retryes, then the conveying mechanism is kept stationary and the UV curing mechanism (3) is turned off, and step S9 is executed; Step S4, Retrieval of Formula: The PLC controller queries and retrieves the corresponding curing formula parameters in the curing formula database of the industrial control computer according to the model code in the decoded product code. The curing formula parameters include UV band, UV power and conveyor belt (1) speed. Step S5, timing control: The PLC controller sends a lighting command to the UV curing mechanism (3) according to the retrieved curing formula parameters, and sends a start command to the conveying mechanism after a delay of 500 milliseconds after sending the lighting command; During the operation of the conveying mechanism, the UV curing mechanism (3) continuously maintains the set power until the rear barcode camera (9) completes scanning or the product completely leaves the UV curing area; Step S6, UV curing: The product enters the UV curing zone along with the conveying mechanism, and the UV curing mechanism (3) emits ultraviolet light to the product according to the curing formula parameters retrieved; Step S7, Automatic Scanning: The product code carried by the solidified product is identified by the rear scanning camera (9); Step S8, subsequent QR code verification: The PLC controller determines whether the product code was successfully obtained in step S7, and whether the product code is consistent with the product code obtained in step S2; If they match, proceed to step S10; if they do not match or the acquisition fails, generate an exception flag and proceed to step S10. Step S9, Abnormal Handling: The PLC controller controls the touch screen (6) to display the barcode scanning failure prompt and controls the buzzer (7) to emit an intermittent alarm sound to maintain the abnormal pause state; after receiving the reset command triggered by the operator, the PLC controller clears the alarm state and returns to step S1; or after receiving the manual release command with administrator privileges, it forcibly starts the conveying mechanism and the UV curing mechanism (3) to execute the UV curing step, and controls the industrial control computer to record the manual release abnormal log, and then executes step S10; Step S10, Data Association and Storage: The PLC controller sends the product code obtained by the previous scan, the product code obtained by the subsequent scan, the abnormal mark, and the manual release abnormal log to the industrial control computer for association and storage, forming a complete solidified record, and then returns to step S1; Step S11, Emergency Stop Processing: During any of the execution processes from Step S1 to Step S10, when the emergency stop button (8) is pressed, the PLC controller immediately cuts off the power supply to the UV curing mechanism (3) and the conveying mechanism, and locks the fault state; after the emergency stop button (8) is rotated to reset and a fault reset command is received, a self-test is performed, and after the self-test passes, the process returns to Step S1.

8. The energy-saving and consumption-reducing method of the automatic control and error-proof system for LED UV curing equipment according to claim 7, characterized in that: In step S3, the effective decoding condition refers to: successfully extracting the complete product code data block from a single captured image, and verifying the data integrity and absence of errors through a verification algorithm; for QR codes, successful decoding is allowed within the error correction rate range of 15% to 25%; for barcodes, partial character substitution is not allowed. The UV curing mechanism (3) will increase its output power to more than 98 percent of the set value within 500 milliseconds after receiving the lighting command.

9. The energy-saving and consumption-reducing method of the automatic control and error-proof system for LED UV curing equipment according to claim 7, characterized in that: In step S6, the PLC controller, based on the UV band parameters in the retrieved curing formula parameters, individually turns on or off any one of the 365nm band LED UV lamp heads and the 405nm band LED UV lamp heads, or turns on both groups simultaneously. The PLC controller sets the output power of the UV curing mechanism (3) according to the retrieved UV power parameters, and sets the operating speed of the conveyor motor (2) according to the retrieved conveyor belt (1) speed parameters. During the curing process, the PLC controller monitors the equipment over-temperature signal and motor overload signal in real time. When over-temperature or overload occurs, it immediately cuts off the power supply to the UV curing mechanism (3) and the conveying motor (2), records the fault log, and then returns to step S1.

10. The energy-saving and consumption-reducing method of the automatic control and error-proof system for LED UV curing equipment according to claim 7, characterized in that: In step S10, the curing record includes the complete product code, previous scan timestamp, subsequent scan timestamp, curing duration, formula name used, actual UV power, actual delivery speed, equipment number, and operator ID; the industrial computer provides a curing history query interface, which supports searching by product code, curing date and time period, product model code, and at least one condition in the curing result, and supports exporting to CSV or Excel format files; The solidified formula database is password protected, allowing only authorized administrators to modify formula parameters, and the industrial control computer records formula modification logs; The industrial control computer uses a cyclic overwrite storage strategy for the fixed records. When the storage capacity reaches a preset threshold, the earliest historical records from three months ago are automatically deleted.

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